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Helical Face Gear Development Under the Enhanced Rotorcraft Drive System Program

U.S. Army goals for the Enhanced Rotorcraft Drive System Program are to achieve a 40 percent increase in horsepower to weight ratio, a 15 dB reduction in drive system generated noise, 30 percent reduction in drive system operating, support, and acquisition cost, and 75 percent automatic detection of critical mechanical component failures. Boeing s technology transition goals are that the operational endurance level of the helical face gearing and related split-torque designs be validated to a TRL 6, and that analytical and manufacturing tools be validated. Helical face gear technology is being developed in this project to augment, and transition into, a Boeing AH-64 Block III split-torque face gear main transmission stage, to yield increased power density and reduced noise. To date, helical face gear grinding development on Northstar s new face gear grinding machine and pattern-development tests at the NASA Glenn/U.S. Army Research Laboratory have been completed and are described.

Heath, Gregory F.

TRISO Spent Nuclear Fuel Recycling or Waste Reduction Using SRNL Vapor Digestion Technology – 25635

There is a renewed interest in advanced reactors, including high-temperature gas cooled reactors (HTGRs). Tri-structural isotropic (TRISO) fuel is being used in many HTGR designs, whether as SMRs or microreactors. However, TRISO-based HTGRs discharge the largest volume of used fuel per megawatt-hour of energy produced compared to other reactors. An order of magnitude reduction or more in the volume of SNF could be realized if the TRISO particles were separated from the graphite moderator and the carbon dispositioned as LLW. The Savannah River National Laboratory (SRNL) has a patented technology readiness level (TRL) 4/5 vapor digestion process for separating nuclear-grade graphite from HTGR SNF. The SRNL process is based on the reaction of NOx species with carbon to form CO2. Because NOx species are several orders of magnitude more reactive with graphite than oxygen, the process can operate at lower temperatures with uncrushed HTGR pebbles or prismatic blocks. Because the fuel elements do not need to be crushed and the graphite is digested using a vapor-based process, the potential for damaging the TRISO particles is much reduced. The DOE Office of Technology Transitions (OTT) is funding SRNL and the University of South Carolina at Columbia to close certain gaps that exist within the technology which impede its direct application to the processing of commercial TRISO-based SNF coming from HTGR advanced reactors.

Pierce, Robert [Savannah River National Laboratory

Transforming the "Valley of Death" into a "Valley of Opportunity"

Transitioning technology from research to operations (23 R2O) is difficult. The problem's importance is exemplified in the literature and in every failed attempt to do so. Although the R2O gap is often called the "valley of death", a recent a Space Weather editorial called it a "Valley of Opportunity". There are significant opportunities for space weather organizations to learn from the terrestrial experience. Dedicated R2O organizations like those of the various NOAA testbeds and collaborative "proving ground" projects take common approaches to improving terrestrial weather forecasting through the early transition of research capabilities into the operational environment. Here we present experience-proven principles for the establishment and operation of similar space weather organizations, public or private. These principles were developed and currently being demonstrated by NASA at the Applied Meteorology Unit (AMU) and the Short-term Prediction Research and Transition (SPoRT) Center. The AMU was established in 1991 jointly by NASA, the U.S. Air Force (USAF) and the National Weather Service (NWS) to provide tools and techniques for improving weather support to the Space Shuttle Program (Madura et al., 2011). The primary customers were the USAF 45th Weather Squadron (45 WS) and the NWS Spaceflight Meteorology Group (SMG who provided the weather observing and forecast support for Shuttle operations). SPoRT was established in 2002 to transition NASA satellite and remote-sensing technology to the NWS. The continuing success of these organizations suggests the common principles guiding them may be valuable for similar endeavors in the space weather arena.

Jedlovec, Gary J.

Technology Directions for the 21st Century, volume 1

For several decades, semiconductor device density and performance have been doubling about every 18 months (Moore's Law). With present photolithography techniques, this rate can continue for only about another 10 years. Continued improvement will need to rely on newer technologies. Transition from the current micron range for transistor size to the nanometer range will permit Moore's Law to operate well beyond 10 years. The technologies that will enable this extension include: single-electron transistors; quantum well devices; spin transistors; and nanotechnology and molecular engineering. Continuation of Moore's Law will rely on huge capital investments for manufacture as well as on new technologies. Much will depend on the fortunes of Intel, the premier chip manufacturer, which, in turn, depend on the development of mass-market applications and volume sales for chips of higher and higher density. The technology drivers are seen by different forecasters to include video/multimedia applications, digital signal processing, and business automation. Moore's Law will affect NASA in the areas of communications and space technology by reducing size and power requirements for data processing and data fusion functions to be performed onboard spacecraft. In addition, NASA will have the opportunity to be a pioneering contributor to nanotechnology research without incurring huge expenses.

Crimi, Giles F.

Research to Operations: The Critical Transition

Space Life Sciences Directorate (SLSD) specializes in transitioning technology and knowledge to medical operations. This activity encompasses funding a spectrum of research and technology efforts, such as understanding fundamental biological mechanisms altered by microgravity and executing technology watches for state of the art diagnostic imaging equipment. This broad spectrum approach to fulfilling the need to protect crewmember health and performance during long and short duration missions to the International Space Station, moon and Mars is made possible by having a line of site between research and operations. Currently, SLSD's line of site is articulated in a transition to medical practice (TMP) process. This process is designed to shepherd information and knowledge gained through fundamental and mechanistic research toward the development of an operational solution such as a pre-flight selection criteria; an in-flight countermeasure, monitoring capability or treatment; or a post-flight reconditioning program. The TMP process is also designed to assist with the customization of mature hardware or technology for NASA specific use. The benefits of this process are that the concept of operational usability is interjected early in the research, design, or acquisition phase, and stakeholders are involved early to identify requirements and also periodically asked to assess requirements compliance of research or technology development project. Currently a device known as the actiwatch is being assessed for the final transition to operational use. Specific examples of research to operations transition success help to illustrate the process and bolster communication between the research and medical operations communities.

Fogarty, Jennifer A.

Energy I-Corps Annual Report 2024

The U.S. Department of Energy Office of Technology Transitions is pleased to provide an update on the Energy I-Corps program. Now in its ninth year, Energy I-Corps delivers workforce development training and funding support to accelerate clean energy technology commercialization. As of November 2024, 243 teams from 13 National Labs have participated in Energy I-Corps over the course of 19 cohorts and the pilot. Post Energy I-Corps, technologies have attracted more than $197 million in post-program funding and executed 85 licenses.

commercialization

Energy-Transit Nexus Tools for Bus Fleet Electrification (NEXTBUS)

NEXTBUS is an open-source software project that integrates NLR's bus energy modeling and simulation tools with multi-objective optimization for fleet operations. NLR is collaborating with a transit technology startup, ReVolt, to commercialize these capabilities by deploying NEXTBUS in ReVolt's software platform. The goal is to manage the added complexities of running a heterogeneous fleet, encompassing battery electric and diesel buses, across a large, multi-depot transit network.

33 ADVANCED PROPULSION SYSTEMS

Transitioning Autonomous Systems Technology Research to a Flight Software Environment

NASA has developed methods and algorithms for autonomous spacecraft operations,including automated planning and scheduling, fault diagnostics and impact determination,procedure management and display. Making the transition from technology research tooperational flight software requires overcoming significant technical, programmatic andcultural challenges. Technology research is aimed at developing methods that performspecific functions correctly, but the resulting software may not be designed for flightprocessors with limited CPU, memory and network resources, and may not be easilyintegrated into spacecraft flight software. Our objective in the Autonomous Systems andOperations Project is to make significant strides toward the transformation from technologyto operational use. Our focus was twofold: maturing research grade autonomy software intoa flight software environment using broadly accepted languages and tools; and integratingautonomy applications with each other and with representative systems and their data andcommand interfaces. For a target flight software environment, we chose Core FlightSoftware, developed by Goddard Space Flight Center as a common operating systemindependent framework. Our hardware integration environment was provided by theIntegrated Power and Avionics Systems (iPAS) Lab at Johnson Space Center, in whichvarious subsystem development has been conducted to address engineering challenges forthe vehicles and systems required for long-duration missions into the solar system. The iPASand its network of connected facilities provides realistic subsystem hardware or simulationsof spacecraft power, life support, guidance, navigation and control, and command and datahandling subsystems. Interfaces between autonomy applications and the subsystems beingassessed and controlled were developed, assessed and refined. The hardware and softwareenvironment using CFS and the iPAS facility has proven to be a highly flexible and realisticenvironment in which to rapidly integrate applications in an iterative, low cost setting. Usingthe integration environment we have developed, we will turn our focus to performance andsizing analysis to determine the computational requirements for full-scale deployment ofautonomy technology. Scalability of reasoners and the spacecraft models upon which theyoperate, and robustness across the full range of spacecraft conditions and environments willbe explored and improved. We are making significant contributions to the future programsthat will build the spacecraft that will take humans beyond the Earth-Moon system, in whichprogram Systems Engineers will be able to accurately and confidently design in accurate,robust and mature autonomous operations systems.

Flight Software

Dithionite Inhibits Iron(III) (Hydr)oxide Formation during Olivine Dissolution Advancing Simultaneous CO 2 Mineralization and Nickel Recovery

Increasing CO 2 concentration poses significant global challenges, impacting both environmental and human health. As we strive for a carbon-neutral energy technology transition, the demand for critical elements (e.g., nickel and cobalt) continues to increase, while high-grade ores are depleting. Combining CO 2 mineralization with the recovery of critical elements from low-grade ores offers an innovative solution. Olivine, a magnesium-rich ultramafic with trace amounts of critical elements, is a promising mineral; however, its impurities, such as iron (Fe(III)), hinder the dissolution of Ni and Mg from olivine, reducing its carbonation and critical element recovery. Here, to address this challenge, this study examined Ni dissolution from San Carlos olivine at high temperatures and high CO 2 pressure. We found that iron(III) (hydr)oxide layers impeded olivine dissolution; however, with sodium dithionite (Na 2 S 2 O 4 ), a reducing agent, olivine dissolution is significantly improved by preventing iron(III) (hydr)oxide formation. With Na 2 S 2 O 4 , within 24 h, Mg and Ni dissolution from olivine increased 2.85-fold and 2.66-fold, respectively, compared to samples without Na 2 S 2 O 4 . After seven cycles, with solutions replaced every 24 h, 98.9% of the total Mg and 84.6% of the total Ni were recovered. This approach enhances olivine’s CO 2 mineralization and improves the sustainability of critical element supply.

54 ENVIRONMENTAL SCIENCES

Tailoring MoS 2 for Small-Molecule Electroreduction: The Role of Metal Doping and Heterostructures

The electrification of chemical transformations central to sustainable fuel production and waste valorization, such as overall water splitting (OWS), hydrogen evolution reaction (HER), and electrochemical reduction of CO 2 (CO 2 R), presents a powerful opportunity to advance carbon-neutral energy technologies. Transition metal dichalcogenides (TMDs), particularly MoS 2 , have emerged as promising electrocatalyst candidates, owing to their abundance, tunable active sites, and defect-rich structures. This review highlights recent progress in leveraging metal doping and heterostructure engineering of MoS 2 to enhance the electrocatalytic activity and selectivity. By compiling insights from experimental studies and density functional theory (DFT) predictions, we examine how defect creation, electronic structure modification, and interface design contribute to improved charge transport and catalytic efficiency. Particular emphasis is placed on rational design principles, synthetic strategies, and operando characterization methods that provide a pathway to understanding and optimizing MoS 2 -based materials. We also discuss the challenges of stability, mechanistic ambiguity, and scaling while outlining opportunities to bridge theory and experiment. Collectively, this review underscores how defect and heterostructure engineering of MoS 2 can accelerate the development of efficient, sustainable electrocatalysts for both fuel generation and waste-to-value generation.

CO2 reduction

Machine Learning for Predictive Performance Analysis in Charged Particle Beam Tools

Imaging methods driven by probes, electrons, and ions have played a dominant role in modern science and engineering. Opportunities for machine vision and AI that focus on consumer problems like driving and feature recognition, are now presenting themselves for automating aspects of the scientific processes. This proposal aims to enable and drive discovery in ultra-low energy implantation by taking advantage of faster processing, flexible control and detection methods, and architecture-agnostic workflows that will result in higher efficiency and shorter scientific development cycles. Custom microscope control, collection and analysis hardware will provide a framework for conducting novel in situ experiments revealing unprecedented insight into surface dynamics at the nanoscale. Ion implantation is a key capability for the semiconductor industry. As devices shrink, novel materials enter the manufacturing line, and quantum technologies transition to being more mainstream. Traditional implantation methods fall short in terms of energy, ion species, and positional precision. Here we demonstrate 1 keV focused ion beam Au implantation into Si and validate the results via atom probe tomography. We show the Au implant depth at 1 keV is 0.8 nm and that identical results for low energy ion implants can be achieved by either lowering the column voltage, or decelerating ions using bias – while maintaining a sub-micron beam focus. We compare our experimental results to static calculations using SRIM and dynamic calculations using binary collision approximation codes TRIDYN and IMSIL. A large discrepancy between the static and dynamic simulation is found that is due to lattice enrichment with high stopping power Au and surface sputtering. Additionally, we demonstrate how model details are particularly important to the simulation of these low-energy heavy-ion implantations. Finally, we discuss how our results pave a way to much lower implantation energies, while maintaining high spatial resolution.

47 OTHER INSTRUMENTATION

RPRV research focus on HiMAT

A review is presented of the F-15 Remotely Piloted Research Vehicle (RPRV) project. The F-15 RPRV is air-launched from a B-52 at 50,000 ft. Following launch a series of research maneuvers are performed during an unpowered descent to a recovery altitude. Another RPRV program considered is the Highly Maneuverable Aircraft Technology (HiMAT) program. This program is designed to use RPRVs to speed the technology transition from wind tunnel to flight and to reduce the cost of aeronautical experiments. It is pointed out that HiMAT will make extensive use of composite materials.

Lockenour, J. L.

AdaNET research project

The components necessary for the success of the commercialization of an Ada Technology Transition Network are reported in detail. The organizational plan presents the planned structure for services development and technical transition of AdaNET services to potential user communities. The Business Plan is the operational plan for the AdaNET service as a commercial venture. The Technical Plan is the plan from which the AdaNET can be designed including detailed requirements analysis. Also contained is an analysis of user fees and charges, and a proposed user fee schedule.

Digman, R. Michael

Viscous drag reduction in boundary layers

The present volume discusses the development status of stability theory for laminar flow control design, applied aspects of laminar-flow technology, transition delays using compliant walls, the application of CFD to skin friction drag-reduction, active-wave control of boundary-layer transitions, and such passive turbulent-drag reduction methods as outer-layer manipulators and complex-curvature concepts. Also treated are such active turbulent drag-reduction technique applications as those pertinent to MHD flow drag reduction, as well as drag reduction in liquid boundary layers by gas injection, drag reduction by means of polymers and surfactants, drag reduction by particle addition, viscous drag reduction via surface mass injection, and interactive wall-turbulence control.

Bushnell, Dennis M.

Lessons learned for composite structures

Lessons learned for composite structures are presented in three technology areas: materials, manufacturing, and design. In addition, future challenges for composite structures are presented. Composite materials have long gestation periods from the developmental stage to fully matured production status. Many examples exist of unsuccessful attempts to accelerate this gestation period. Experience has shown that technology transition of a new material system to fully matured production status is time consuming, involves risk, is expensive and should not be undertaken lightly. The future challenges for composite materials require an intensification of the science based approach to material development, extension of the vendor/customer interaction process to include all engineering disciplines of the end user, reduced material costs because they are a significant factor in overall part cost, and improved batch-to-batch pre-preg physical property control. Historical manufacturing lessons learned are presented using current in-service production structure as examples. Most producibility problems for these structures can be traced to their sequential engineering design. This caused an excessive emphasis on design-to-weight and schedule at the expense of design-to-cost. This resulted in expensive performance originated designs, which required costly tooling and led to non-producible parts. Historically these problems have been allowed to persist throughout the production run. The current/future approach for the production of affordable composite structures mandates concurrent engineering design where equal emphasis is placed on product and process design. Design for simplified assembly is also emphasized, since assembly costs account for a major portion of total airframe costs. The future challenge for composite manufacturing is, therefore, to utilize concurrent engineering in conjunction with automated manufacturing techniques to build affordable composite structures. Composite design experience has shown that significant weight savings have been achieved, outstanding fatigue and corrosion resistance have been demonstrated, and in-service performance has been very successful. Currently no structural design show stoppers exist for composite structures. A major lesson learned is that the full scale static test is the key test for composites, since it is the primary structural 'hot spot' indicator. The major durability issue is supportability of thin skinned structure. Impact damage has been identified as the most significant issue for the damage tolerance control of composite structures. However, delaminations induced during assembly operations have demonstrated a significant nuisance value. The future challenges for composite structures are threefold. Firstly, composite airframe weight fraction should increase to 60 percent. At the same time, the cost of composite structures must be reduced by 50 percent to attain the goal of affordability. To support these challenges it is essential to develop lower cost materials and processes.

Whitehead, R. S.

Progress towards computer simulation of NiH2 battery performance over life

The long-term performance of rechargeable battery cells has traditionally been verified through life-testing, a procedure that generally requires significant commitments of funding and test resources. In the situation of nickel hydrogen battery cells, which have the capability of providing extremely long cycle life, the time and cost required to conduct even accelerated testing has become a serious impediment to transitioning technology improvements into spacecraft applications. The utilization of computer simulations to indicate the changes in performance to be expected in response to design or operating changes in nickel hydrogen cells is therefore a particularly attractive tool in advanced battery development, as well as for verifying performance in different applications. Computer-based simulations of the long-term performance of rechargeable battery cells have typically had very limited success in the past. There are a number of reasons for the lack in progress in this area. First, and probably most important, all battery cells are relatively complex electrochemical systems, in which performance is dictated by a large number of interacting physical and chemical processes. While the complexity alone is a significant part of the problem, in many instances the fundamental chemical and physical processes underlying long-term degradation and its effects on performance have not even been understood. Second, while specific chemical and physical changes within cell components have been associated with degradation, there has been no generalized simulation architecture that enables the chemical and physical structure (and changes therein) to be translated into cell performance. For the nickel hydrogen battery cell, our knowledge of the underlying reactions that control the performance of this cell has progressed to where it clearly is possible to model them. The recent development of a relative generalized cell modelling approach provides the framework for translating the chemical and physical structure of the components inside a cell into its performance characteristics over its entire cycle life. This report describes our approach to this task in terms of defining those processes deemed critical in controlling performance over life, and the model architecture required to translate the fundamental cell processes into performance profiles.

Zimmerman, Albert H.

Advanced Stirling Convertor Testing at NASA Glenn Research Center

The NASA Glenn Research Center (GRC) has been testing high-efficiency free-piston Stirling convertors for potential use in radioisotope power systems (RPSs) since 1999. The current effort is in support of the Advanced Stirling Radioisotope Generator (ASRG), which is being developed by the U.S. Department of Energy (DOE), Lockheed Martin Space Systems Company (LMSSC), Sunpower, Inc., and the NASA GRC. This generator would use two high-efficiency Advanced Stirling Convertors (ASCs) to convert thermal energy from a radioisotope heat source into electricity. As reliability is paramount to a RPS capable of providing spacecraft power for potential multi-year missions, GRC provides direct technology support to the ASRG flight project in the areas of reliability, convertor and generator testing, high-temperature materials, structures, modeling and analysis, organics, structural dynamics, electromagnetic interference (EMI), and permanent magnets to reduce risk and enhance reliability of the convertor as this technology transitions toward flight status. Convertor and generator testing is carried out in short- and long-duration tests designed to characterize convertor performance when subjected to environments intended to simulate launch and space conditions. Long duration testing is intended to baseline performance and observe any performance degradation over the life of the test. Testing involves developing support hardware that enables 24/7 unattended operation and data collection. GRC currently has 14 Stirling convertors under unattended extended operation testing, including two operating in the ASRG Engineering Unit (ASRG-EU). Test data and high-temperature support hardware are discussed for ongoing and future ASC tests with emphasis on the ASC-E and ASC-E2.

Wilson, Scott D.

Automated Data Production For A Novel Airborne Multiangle Spectropolarimetric Imager (AIRMSPI)

A novel polarimetric imaging technique making use of rapid retardance modulation has been developed by JPL as a part of NASA's Instrument Incubator Program. It has been built into the Airborne Multiangle SpectroPolarimetric Imager (AirMSPI) under NASA's Airborne Instrument Technology Transition Program, and is aimed primarily at remote sensing of the amounts and microphysical properties of aerosols and clouds. AirMSPI includes an 8-band (355, 380, 445, 470, 555, 660, 865, 935 nm) pushbroom camera that measures polarization in a subset of the bands (470, 660, and 865 nm). The camera is mounted on a gimbal and acquires imagery in a configurable set of along-track viewing angles ranging between +67 deg and -67 deg relative to nadir. As a result, near simultaneous multi-angle, multi-spectral, and polarimetric measurements of the targeted areas at a spatial resolution ranging from 7 m to 20 m (depending on the viewing angle) can be derived. An automated data production system is being built to support high data acquisition rate in concert with co-registration and orthorectified mapping requirements. To date, a number of successful engineering checkout flights were conducted in October 2010, August-September 2011, and January 2012. Data products resulting from these flights will be presented.

Multi-angle